Device and process for refueling containers with pressurized gas

ABSTRACT

A device and process for refuelling containers with pressurized gas comprising a pressurized gas source, a transfer circuit comprising one upstream end, the device comprising a refrigeration system for cooling the gas flowing from the gas source prior to its entering into the container, the refrigeration system comprising a refrigerant cooling loop circuit comprising, arranged in series, a compressor, a condenser section, an expansion valve and an evaporator section, the refrigeration system comprising a cold source in heat exchange with the condenser section and a heat exchanger located in the transfer circuit and comprising a heat exchange section between the gas flowing in the transfer circuit and the evaporator section, the refrigerant cooling loop circuit comprising a bypass conduit comprising an upstream end connected to the outlet of the compressor and a downstream end connected to the refrigerant cooling loop circuit upstream the compressor inlet and bypassing the condenser section and expansion valve, the device comprising a bypass regulating valve for controlling the flow of refrigerant flowing into the by-pass conduit.

CROSS-REFERENCE TO RELATED APPLICATIONS

This application claims the benefit of priority under 35 U.S.C. § 119(a) and (b) to Japanese patent application No. JP 2018-145245, filedAug. 1, 2018, and EP patent application no. EP18306043, filed Aug. 1,2018, the entire contents of which are incorporated herein by reference.

BACKGROUND Field of the Invention

The invention relates to a device and process for refuelling containerswith pressurized gas.

The invention relates more particularly to a device for refuellingcontainers with pressurized gas, notably for refuelling gaseous hydrogentanks, comprising a pressurized gas source, a transfer circuitcomprising one upstream end connected to the gas source and at least onedownstream end (6) intended to be removably connected to a container,the device comprising a refrigeration system for cooling the gas flowingfrom the gas source prior to its entering into the container, therefrigeration system comprising a refrigerant cooling loop circuitcomprising, arranged in series, a compressor, a condenser section, anexpansion valve and an evaporator section, the refrigeration systemcomprising a cold source in heat exchange with the condenser section anda heat exchanger located in the transfer circuit and comprising a heatexchange section between the gas flowing in the transfer circuit and theevaporator section.

Related Art

Hydrogen refuelling stations are designed for fast refuelling (fewminutes) of Fuel Cell Electrical Vehicles (FCEV) with hydrogen at highpressure (for example equal or above 70 MPa). Hydrogen needs to beprecooled (generally below −33° C.) at dispenser refuelling nozzle inorder to avoid overheating in the tank.

A known cooling or refrigeration system feeds a hydrogen cooling heatexchanger with a refrigerant of a refrigerant cooling loop circuit.

Refrigerant may be CO₂. See for example documents JP20150921108A orUS2016348840A. See also WO2018104983A1.

Generally, the heat exchanger includes a mass or block of material forstoring cold for responding to high demand. The refrigeration device mayprovide nearly constant cooling and the cooling energy is stored in thethermal inertia of the heat exchanger (high thermal inertia).

However, the thermal inertia may be not sufficient in some situations toprovide the cold needed. In addition, when using another type of heatexchanger (ex: a compact diffusion bonded heat exchanger) the thermalinertia is small. In that cases, the cooling energy has to be providedwhen there is a demand. This demand might change within seconds fromzero to full cooling power.

Most efficient use of the cooling power is done using counter-currentheat exchanger. In that case, it is desirable that the temperature ofthe refrigerant at the inlet to the heat exchanger remains in apre-determined range of temperature.

For that purpose, pre-determined evaporation pressure range should bemaintained at the inlet of the heat exchanger. Also, sufficientsuperheat should be maintained at the suction of the compressor.Superheat is for example the predetermined amount of heat added to therefrigerant after it has already vaporized. It can be defined by atemperature at a given pressure and may be measured at the outlet of theheat exchanger or at compressor inlet. The evaporation temperature ofthe refrigerant depends on pressure.

The reason why superheat is controlled is to make sure that the liquidrefrigerant in the evaporator section has fully changed from a liquid tovapour (since it is wanted to have only vapour returning to thecompressor suction/inlet).

The refuelling device (or station) may also be set in standby mode(waiting situation for refuelling) for an extended time. And even ifthere is a refuelling, the amount of gas might below the maximum designvalues. In those cases, the refrigeration system will operate at lowload.

SUMMARY OF THE INVENTION

One goal is to overcome or reduce at least one of the precedingproblems.

To this end, the device according the invention, according to thegeneric definition above, is essentially characterized in that therefrigerant cooling loop circuit comprises a bypass conduit comprisingan upstream end connected to the outlet of the compressor and adownstream end connected to the refrigerant cooling loop circuitupstream the compressor inlet and bypassing the condenser section andexpansion valve, the device comprising a bypass regulating valve forcontrolling the flow of refrigerant flowing into the by-pass conduit.

This given quantity of hot compressed bypass gas which is reinjectedupstream the compressor allows to rise the refrigerant temperature andpressure at compressor inlet. This allows also to vary the quantity ofrefrigerant flowing through the evaporator. In case of full coolingcapacity needed, the bypass valve can be closed.

In addition, (or alternatively), embodiments might include one orseveral of the below features:

-   -   the downstream end of the bypass conduit is connected at the        outlet of the heat exchanger of the transfer circuit,    -   the bypass valve is a controlled valve able to be set in a        closed position or a plurality of open positions for varying the        flowrate of refrigerant flowing in the bypass conduit, the        device comprising an electronic controller connected to the        bypass valve and configured for controlling the opening of said        the bypass valve,    -   the compressor is a variable speed compressor and in that the        electronic controller is connected to the compressor and        configured for controlling the compressor (8) and notably the        compressor speed,    -   the electronic controller is connected to the expansion valve        and configured for controlling the cooling power produced by the        refrigeration system via the control of the opening of the        expansion valve,    -   the device comprises a differential temperature sensor system        measuring the difference between the temperature of the        refrigerant in the refrigerant cooling loop circuit at the        outlet of the heat exchanger and the temperature of the        refrigerant in the cooling loop circuit at the inlet of the heat        exchanger, the electronic controller being configured for        controlling the cooling power produced as a function of this        temperature differential,    -   the electronic controller is configured to generate or receive a        signal indicative of the cooling power needed at heat exchanger        for cooling the flow of gas in the transfer circuit through the        heat exchanger and, in response, for controlling the cooling        power produced by the refrigeration accordingly,    -   the signal indicative of the cooling power needed at the heat        exchanger comprises at least one among: the quantity or the        flowrate of gas flowing through the transfer circuit, the        temperature of the gas flowing through the transfer circuit, the        pressure of the gas flowing through the transfer circuit, a        pressure value or pressure change in the gas source, an external        demand such as a wireless signal,    -   the process comprises a step of controlling the cooling power        produced in the evaporator section of the refrigerant cooling        loop circuit via the control of the opening of the expansion        valve,    -   the device comprises and expansion vessel comprising an inlet        connected to the refrigerant cooling loop circuit downstream the        compressor outlet and an outlet connected to the refrigerant        cooling loop circuit upstream the compressor inlet, the device        comprising a set of valve(s) for controlling the flow of        refrigerant to the expansion vessel and from the expansion        vessel for controlling the pressure in the refrigerant cooling        loop circuit and in the expansion vessel,    -   the device comprises a pressure sensor for sensing the        refrigerant pressure in the cooling loop circuit between the        compressor inlet and the heat exchanger outlet, notably at the        inlet of the compressor,    -   the electronic controller is configured for regulating the        suction pressure at the inlet of the compressor on a        predetermined pressure set point via the control of the        compressor speed and the opening of the bypass valve,    -   the device comprises a temperature sensor for sensing the        refrigerant temperature in the refrigerant cooling loop circuit        between the compressor inlet and the heat exchanger outlet and,        notably at the inlet of the compressor,    -   the electronic controller is configured for regulate the        temperature of the refrigerant at the inlet of the compressor on        a predetermined temperature set point via a control of the        compressor speed and the opening of the bypass valve,    -   the electronic controller is configured for regulating the        temperature of the refrigerant at the inlet of the heat        exchanger on a predetermined temperature set point via a control        of the compressor speed and the opening of the bypass valve,    -   the device comprises a temperature sensor for sensing the heat        exchanger temperature, the electronic controller being        configured to be able to switch the refrigeration system in        first standby mode, in the first standby mode, when the        temperature of the heat exchanger is equal or below a predefined        first standby temperature threshold, for example comprised        between −40° C. and −20° C., the electronic controller switches        off the compressor, and when the sensed temperature of the heat        exchanger is above a second standby threshold, for example equal        or above the first standby temperature threshold, the electronic        controller starts the compressor for producing cooling power and        cooling the heat exchanger.    -   the electronic controller is configured in the first standby        mode for starting the cold source when the sensed pressure in        the refrigerant cooling loop circuit is above a preset standby        pressure threshold and thus lowering the pressure in the        refrigerant cooling loop circuit,    -   the electronic controller is configured in the first standby        mode for starting the compressor when the sensed pressure in the        refrigerant cooling loop circuit is above a preset standby        pressure threshold and thus lowering the pressure in the        refrigerant cooling loop circuit,    -   the cold source and the compressor are both started when the        heat exchanger 7 must be cooled,

The invention also deals with a process for refuelling containers withpressurized gas, notably for refuelling gaseous hydrogen tanks, with adevice comprising gas source, a transfer circuit for transferringcompressed gas from the gas source to a container, the processcomprising a step of cooling a heat exchanger located in the transfercircuit, the heat exchanger being in heat exchange with the gas flowingfrom the source to the container(s), the step of cooling comprising theproduction of a cooling power in a evaporator section of a refrigerantcooling loop circuit, the cooling loop circuit comprising, arranged inseries, a compressor, a condenser section, an expansion valve and theevaporator section, the condenser section being in heat exchange with acold source, the process comprising the step of controlling the quantityrefrigerant compressed by the compressor which is reinjected via abypass conduit upstream the compressor, without flowing via thecondenser section and the expansion valve.

According to other embodiments, the invention can include one or severalof the below features:

-   -   the compressed gas reinjected via a bypass conduit upstream the        compressor is reinjected at the outlet of the heat exchanger,    -   the process comprises a step of regulating the suction pressure        at the inlet of the compressor to a predetermined pressure level        via the control of the compressor speed and the quantity of        refrigerant reinjected via a bypass conduit upstream the        compressor,    -   the process comprises a step regulating the temperature of the        refrigerant at the inlet of the compressor on a predetermined        temperature set point via the control of the compressor speed        and the degree of opening of the bypass valve,    -   the process comprises a step of controlling the cooling power        produced in the evaporator section of the refrigerant cooling        loop circuit as a function of the temperature differential        between the temperature of the refrigerant in the refrigerant        cooling loop circuit at the outlet of the heat exchanger and the        temperature of the refrigerant in the cooling loop circuit at        the inlet of the heat exchanger,    -   the process comprises a step of controlling the cooling power        produced at the evaporator section of the refrigerant cooling        loop circuit as a function of a signal indicative of the cooling        power demand at the heat exchanger, said signal including at        least one among: the quantity or flowrate of gas flowing through        the transfer circuit, the temperature of the gas flowing through        the transfer circuit, the pressure of the gas flowing through        the transfer circuit, a pressure or pressure change in the gas        source, a demand from a user for refuelling a container, a        wireless signal,    -   the process comprises a step of directing some refrigerant of        the refrigerant cooling loop circuit to an expansion vessel for        lowering the pressure in the refrigerant cooling loop circuit        below a predetermined value,    -   when the pressure in the expansion vessel is above a        predetermined value, the process comprises a step providing cold        to the refrigerant cooling loop circuit via the cold source and        withdrawing gas from the expansion vessel to the refrigerant        cooling loop circuit,    -   the process comprises a step of switching the device in a first        standby mode when there is not demand for refuelling a        container, in the first standby mode the compressor being        switched on when the temperature of the heat exchanger is equal        or below a predefined first standby temperature threshold, for        example comprised between −40° C. and −20° C., and wherein the        compressor is started for producing cooling power for cooling        the heat exchanger when the temperature of the heat exchanger is        above a second standby threshold, for example equal or above the        first standby temperature threshold,    -   in the first standby mode, the process comprises a step of        lowering the pressure in the refrigerant cooling loop upstream        of the compressor via the starting of the cold source when the        pressure in the refrigerant cooling loop circuit is above a        preset standby pressure threshold    -   in the first standby mode, the process comprises a step of        lowering the pressure in the refrigerant cooling loop upstream        of the compressor via the starting of the compressor when the        pressure in the refrigerant cooling loop circuit is above a        preset standby pressure threshold,    -   in the first standby mode, the process comprises the step of        starting the compressor for producing cooling power and cooling        the heat exchanger when the temperature of the heat exchanger is        equal or below a predefined first standby temperature threshold,        for example comprised between −40° C. and −20° C., and the step        of switching off the compressor when the temperature of the heat        exchanger is above the predefined first standby temperature        threshold.

The invention mays also relate to any alternative device or processcomprising any combination of the above or below features within thescope of the claims.

BRIEF DESCRIPTION OF THE FIGURES

Other particularities or advantages will be apparent from the reading ofthe below description, referring to the drawings wherein:

FIG. 1 is schematic and partial view showing the structure and operationof a refuelling device according to a first embodiment,

FIG. 2 is schematic and partial view showing the structure and operationof a refuelling device according to a second embodiment,

FIG. 3 is schematic and partial view showing the structure and operationof a refuelling device according to a third embodiment,

FIG. 4 is schematic and partial view showing the structure and operationof a refuelling device according to a fourth embodiment,

FIG. 5 is a schematic and partial view of one possible operation of thedevice and process,

FIG. 6 is a schematic and partial view of a different possible operationof the device and process,

FIG. 7 is a schematic and partial view of a different possible operationof the device and process,

FIG. 8 is a schematic and partial view of a different possible operationof the device and process,

FIG. 9 is schematic and partial view showing the structure and operationof a refuelling device according to a further embodiment.

DETAILED DESCRIPTION OF THE INVENTION

As illustrated in the drawings, the device 1 for refuelling containers 3might be a fuelling station for refuelling a pressurized gas to vehicletanks (for example hydrogen but it may apply to other gases: natural gas. . . ).

The device 1 comprises a pressurized gas source 2, a transfer circuit 4comprising one upstream end 5 connected to the gas source 2 and at leastone downstream end 6 (for example provided with a nozzle) intended to beremovably connected to a container or tank 3 to be filled.

The gas source 2 may include for example at least one among: pressurizedgas storage(s) or buffer(s), compressor(s), bundle(s) of pressurized gascylinders or tube trailers(s), a liquefied gas source and a vaporiser,an electrolyser, and a gas network outlet.

The transfer circuit 4 may comprise a set a valves controlled by anelectronic controller according to a predefined refuelling strategy(pressure increase or rate of pressure increase and/or mass injectedcontrol and/or control of the density in the tank 3 and/or control ofthe temperature increase in the tank 3).

The device 1 comprises a refrigeration system for cooling the gasflowing from the gas source 2 prior to its entering into the container 3(for example to a predefined temperature below 0° C. notably between−33° C. and −40° C.). The cooled gas temperature may also be controlledto vary according to refuelling condition(s) (as a function oftemperature and/or pressure in the tank 3, rate of pressure increase inthe tank 3, flowrate of gas in the transfer circuit 4, the ambienttemperature . . . ).

The refrigeration system comprises a refrigerant cooling loop circuit 20comprising, arranged in series, a compressor 8, a condenser section 9,an expansion valve 10 and an evaporator section 11. The refrigerantflowing in the cooling loop circuit 20 is preferably carbon dioxide butanother refrigerant might be used such as R717 (ammonia), R22, R134a,R404a, R507 or any refrigerant capable of reaching a temperature of atleast −40° C.

The condenser section 9 may include heat exchanger for cooling therefrigerant compressed by the compressor 8.

The refrigeration system comprises a cold source 12 in heat exchangewith the condenser section 9. This cold source 12 may include a coolingfluid circuit such as a loop. For example, air, water, nitrogen or anyappropriate cooling fluid or refrigerant. The cold source may includeany other cold organ or device able to cool the refrigerant such asthermoconvectors, cooling tower or secondary refrigerating cycle. Thecooling fluid from the cold source 12 may be in heat exchange with thecondenser section 9 in a heat exchanger.

The refrigeration system comprises preferably a heat exchanger 7 locatedin the transfer circuit 4 and comprising a heat exchange section betweenthe gas flowing in the transfer circuit 4 and the evaporator section 11.The evaporator section 11 may comprise a circuit (for example coils) inheat exchange with the transfer circuit 4 and/or with a mass of material(aluminum or the like) forming an organ having a high thermal inertiafor storing cold (for example a several centimetres thick metal oraluminum block and/or other material such a Phase Change Material).

According to an advantageous feature, the refrigerant cooling loopcircuit 20 comprises a bypass conduit 13 comprising an upstream endconnected to the outlet of the compressor 8 and a downstream endconnected upstream the compressor 8 in the refrigerant cooling loopcircuit 20 and bypassing the condenser section 9 and expansion valve 10.The refrigeration device comprises a bypass regulating valve 15 forcontrolling the flow of refrigerant flowing into the by-pass conduit 13.

As illustrated in FIG. 1 at least part of: the compressor 8, thecondenser section 9, the cold source 12, the bypass regulating valve,and possibly the expansion valve 10 might be located in a frigorificmodule 14.

As illustrated in FIG. 1, the downstream end of the bypass conduit 13(the upstream is connected to the compressor outlet) may be connecteddirectly to the suction line of the compressor 8. This means that thehot compressed bypassed refrigerant is reinjected directly into theinlet of the compressor 8.

In another embodiment (FIG. 2) the downstream end of the bypass conduit13 may be connected upstream the inlet of the heat exchanger 7. Thissecond solution allows the mixing of the hot compressed bypassedrefrigerant and the colder refrigerant flow regulated by the expansionvalve 10 before entering into the heat exchanger 7. This permits theexpansion valve 10 to maintain superheat level (a sufficienttemperature) in the circuit. This allows also a higher fluid velocity inthe heat exchanger 7 and suction line of the compressor.

In case the compressor is an oil lubricated piston compressor, thisallows to better carry along oil that would have leaked and accumulatedin the refrigerant circuit and especially in the heat exchanger 7.However, at low evaporator load keeping the temperature at the heatexchanger inlet constant might be more difficult to control.

In a preferred embodiment illustrated in FIGS. 3 and 4, the downstreamend of the bypass conduit 13 is connected to the outlet of the heatexchanger 7 of the transfer circuit 4. This is to say the hot compressedbypassed refrigerant is reinjected and mixed with the refrigerantexiting the said heat exchanger 7.

This means that the hot compressed bypassed refrigerant is not injectedin the compressor 8 inlet or suction line but more upstream andpreferably closer to the refrigerant outlet of the heat exchanger 7. Forexample, the downstream end of the bypass conduit 13 is tied up(connected) in the refrigerant cooling loop circuit 20 just after theevaporator 11 section, for example between one cm and forty cm after theoutlet of this evaporator 11 section of after the outlet of the heatexchanger 7.

As detailed below, in case the temperature of the refrigerant exitingthe evaporator 11 (heat exchanger 7) needs to be measured (typically viatemperature sensor 17), the tie in of the bypass conduit 13 should notbe too dose to the outlet of the evaporator 11 since it would influencethe temperature measurement. A possible advantageous solution is tolocated the temperature measurement as dose as possible to the outlet ofthe evaporator 7 (for example around 5-10 cm due to the requiredfittings). The connection of the bypass conduit 13 is thus preferably isaround 20 to 30 cm downstream of the first bend of the refrigerantcircuit downstream the evaporator 7. Since the evaporator 7 is generallymounted inside the gas dispenser and the pipes come from below, thelocation may nearly automatically be defined due to the available space.

Compared to the solution described on FIG. 2, this solution prevents orlowers the problems of a fluctuating temperature at the inlet of theheat exchanger 7 as there is not mixing of hot and cold refrigerant atthe inlet of the heat exchanger 7. Compared to the solution described onFIG. 1, this solution helps oil return and prevents liquid refrigerantaccumulation in the return line of the refrigerant cooling loop circuit20 (i.e. in the line from heat exchanger to the compressor inlet.

Preferably, the bypass valve 15 is a controlled valve able to be set ina closed position or a plurality of open positions or able to be set inopened and closed positions (for example full open and full closed) formodulated periods of time (e.g. Pulse Width Modulation on solenoidvalves for example). This allows interrupting or for varying theflowrate of refrigerant flowing in the bypass conduit 13. The device 1may comprise an electronic controller 21 connected to the bypass valve15 and configured (for example programmed) for controlling the openingof said the bypass valve 15 (see FIG. 4).

The electronic controller 21 may comprise organ(s) for storing treatingreceiving and/or sending data. For example, it comprisesmicroprocessor(s) and/or calculator(s) and/or computer. The electroniccontroller 21 might be located in the device or station or mightdistant. This electronic controller 21 may also control the flow of gasin the transfer circuit 4 to the tank 3.

The compressor 8 is preferably a variable speed compressor. Theelectronic controller 21 might be connected to the compressor 8 andconfigured for controlling the compressor 8 (on/off state) and thecompressor 8 speed.

The cooling power of the refrigeration system may be primarilycontrolled by the opening of expansion valve 10. The controller 21 ispreferably connected to the expansion valve 10 and configured forcontrolling cooling power produced by the refrigeration system via thecontrol of the opening of the expansion valve 10.

In order to maintain a constant evaporation pressure, the suctionpressure upstream the compressor 8, especially at the inlet of heatexchanger 7, has to remain in a predetermined range.

The control of the evaporation pressure might thus be made via thecontrol of the bypass valve 15 and the compressor 8 speed.

The evaporation temperature, i.e. the temperature of the refrigerantafter the expansion valve is depending on the pressure downstream of theexpansion valve 10.

Based on the desired evaporation temperature (for a predeterminedcooling of the refuelling gas) the required suction pressure can becalculated (by mean of appropriate equation of state or correlation).

The pressure can be measured at the exchanger 7 or preferably at thesuction side of the compressor 8. As illustrated in FIG. 4, the devicemay comprise a pressure sensor 16 for sensing the refrigerant pressurein the cooling loop circuit 20 between the compressor 8 inlet and theheat exchanger 7 outlet, notably at the inlet of the compressor 8.

To compensate for pressure losses, a measurement 18 of the temperatureat the inlet of the heat exchanger 7 may be used to decrease thesetpoint of the suction pressure control.

As illustrated in FIG. 4, the device may comprise a temperature sensor18 for sensing the refrigerant temperature in the evaporation section 11upstream the heat exchanger 7, notably at the inlet of the heatexchanger 7.

The suction pressure of the compressor 8 may be controlled with thecontrol of the flow of hot gas admitted in the bypass conduit 13 andwith the speed of the compressor 8.

Zero refrigerant flow through the heat exchanger 7 may be achieved ifthe compressor 8 is at minimum speed (or stopped) and the bypassregulating valve 15 is fully open.

The maximum flow of refrigerant through the heat exchanger 7 is obtainedwhen bypass regulating valve 15 is closed and the compressor 8 is at itsmaximum speed.

This relation might be controlled with a split range control technology.

This permits to make sure that there is always sufficient superheat atthe suction side of the compressor 8.

Fast load changes may result in fast reactions of the expansion valve10. This has an effect on the suction pressure of the compressor 8. Fora fast reaction of the pressure control, the opening of the expansionvalve 10 can be as associated with a feed forward signal to the pressurecontrol output (i.e. by-pass regulating valve 15 and compressor 8 speedset-points).

If the cooling demand increases, the opening of expansion valve 10 isincreased. To keep the evaporation pressure constant, the signal to theexpansion valve 10 may also be used to calculate a feed forward signalto the suction pressure control. This means that the increase of theopening of the expansion valve might command the decrease of theby-passed refrigerant flow and/or the increase of compressor 8 speed.

In typical refrigeration applications, the superheat (refrigeranttemperature) can be measured just after the evaporator section 11 (atthe outlet of the heat exchanger 7).

Alternatively, or in addition, it is possible to measure the superheatcloser to the compressor 8 inlet, for example at the inlet of thefrigorific module 14 (the frigorific module may be named also chiller).

The main reason to measure temperature close to the evaporator section11 (heat exchanger 7) is energy consumption. In the device, the distancebetween the chiller and the dispenser 6 can be used to subcool theliquid refrigerant and increase the temperature of the gaseousrefrigerant at the suction side of the compressor 8. For example,referring to FIG. 4, this can be achieved by running the line betweenoutlet of condensing section 9 and expansion valve 10, along with theline evaporative section 11 and superheat control 22, within the sameheat insulation material or structure. For this reason, the superheatcontrol is preferably controlled closer to the compressor 8 than to theheat exchanger 7.

Thus, the device 1 preferably comprises a temperature sensor 17 forsensing the refrigerant temperature in the refrigerant cooling loopcircuit 20 between the compressor 8 inlet and the heat exchanger 7outlet and, notably a sensor 22 at the inlet of the compressor 8.

The electronic controller 21 can be configured for regulating thetemperature of the refrigerant at the inlet of the compressor 8 in apredetermined temperature range via a control of the compressor 8 speedand the opening of the bypass valve 15.

As illustrated in FIG. 5, based on the actual (measured or calculated)pressure P and the Pressure set-point PS (pressure needed), theelectronic controller acts on the bypass valve 15 and compressor 8.

The control of the cooling power may be based on temperature measure (asuperheat control) at the outlet of the heat exchanger 7. This controlscheme works well when there are only slow changes in cooling demand.However, in case of tanks refuelling station, fast load changes mighthappen. The simple temperature control strategy would fail to keep thegas temperature (example H₂) to be cooled at the right temperature rangefor refuelling (typically between −33° C. and −40° C.).

In a typical refrigeration application, the cooling demand changes arequite slow. In those cases, the reaction speed of the chiller is thusnot important.

For refuelling stations, the cooling demand may change within secondsfrom zero to full cooling power. For this reason, a single temperaturebased control might not be sufficient.

Preferably, the device comprises a differential temperature sensorsystem measuring the difference between the temperature of therefrigerant in the refrigerant cooling loop circuit 20 at the outlet ofthe heat exchanger 7 and the temperature of the refrigerant in thecooling loop circuit 20 at the inlet of the heat exchanger 7. Theelectronic controller 21 may be configured for controlling the coolingpower produced as a function of this temperature differential.

For example, the temperature differential is calculated based ontemperature sensors 17, 18 at outlet and inlet of the heat exchanger 7.

The temperature at the inlet 18 is equal to the evaporation temperaturegiven by the suction pressure. Instead a measuring, a calculated inlettemperature via the suction pressure reacts faster and gives bettercontrol.

In this context the terms “temperature sensor” means a device fordirectly or indirectly measuring a temperature and/or a device forcalculating the temperature based on appropriate parameter(s).

The expansion valve 10 might be control via a closed loop control onrefrigerant temperature difference between inlet 18 and outlet 17 of theheat exchanger 8. When there is no or low cooling power required, (heatexchanger cold in standby mode for example), temperature difference isvery low. As the cooling demand increases, the temperature differenceincreases and the control will cause the expansion valve 10 to open asrequired.

As the actual cooling power is directly linked to the opening of theexpansion valve 10 (typically with proportional and/or modulated openingtimes), a measurement to control if the supplied cooling power is toohigh or too low may thus be the temperature difference betweenrefrigerant inlet and refrigerant outlet to heat exchanger 7.

The device 1 may be switched in a refuelling mode when there is arefuelling demand.

For example, the refuelling mode might be activated upon generating orreceiving in the electronic controller 21 a signal or command. Forexample, a payment/demand from a user and/or when the refuelling nozzle6 is removed from a base dispenser.

After the nozzle 6 is removed it may take some time (for example 10 s to20 s) for the user to attach the nozzle 6 to the car and to activate therefuelling sequence.

When the connection of the nozzle to the tank 3 is made, then a pressurepulse test may be done (about 30 s for example) and the actualrefuelling can then start.

Within a short period after the refuelling starts (for example 30seconds) a predetermined low gas temperature should be reached at thedispenser outlet 6 (for example about −33° C.).

The device can be designed so that within a time period (example 60 s)after the nozzle is removed from its base the heat exchanger 7 is cooledat predetermined temperature (−38° C. for example).

This means that the heat exchanger is subcooled prior to the gas flow inthe transfer circuit 4 to the tank 3.

If the system is in stand-by mode (as described below) when cooling ofheat exchanger 11 prior to the gas flow is requested, electroniccontroller 21 may start compressor 8 and control expansion valve 10 andby-pass regulating valve 15 as described above. This will cause a fastcooling.

The refuelling of a tank 3 can take between 150 s and 500 s for example.During that time, the actual cooling demand may change rapidly. Theserapid changes are typically too fast for a classical control. Tomaintain a stable temperature of the hydrogen a feed forward control ispreferably implemented.

For example, the operating parameters of the refrigeration system willbe based on the actual required cooling energy.

Thus, once the actual refuelling starts, the refuelling will create acooling demand. Based on the actual cooling demand the required coolingpower may be calculated/provided.

The electronic controller 21 may calculate and control the requiredrefrigerant flow in the heat exchanger 7 (as the cooling demandincreases the refrigerant flow has to increase accordingly).

The compressor 8 may start shortly after the refuelling start. To limitthe power consumption, the refrigeration system may cool the internalheat exchanger 9 (condenser section) and the heat exchanger 7 as much aspossible at the beginning.

As the cooling demand increases first the bypass valve 15 might beclosed and then the compressor 8 speed might be increased as required.This can be done via a split range control.

To react faster on load changes, the required cooling power may becalculated based on the gas flow to be cooled. The calculated coolingdemand may act as on offset to the electronic controller 21. Theexpansion valve 10 may thus be opened before a significant change indifferential temperature occurs at the heat exchanger 7.

A feed forward control based on the actual cooling demand may be used.Based on the gas flow in the transfer circuit 4 and the (expected) inlettemperature, the required cooling power may be calculated. Based on therequired cooling power, the required refrigerant flow can be calculatedand then the required opening of the expansion valve 10. The requiredexpansion valve 10 opening may thus be used to generate a feed forwardsignal for the cooling power control.

An estimate of the required cooling power may be calculated using theinstrumentation available on the device 1. For example, the coolingpower required might set equal to the gas flowrate to be cooledmultiplied by the difference between the enthalpy of the gas at theinlet of the heat exchanger 7 and the enthalpy of said gas at the outletof the heat exchanger 7. This can be calculated with the expected outletgas temperature at the nozzle 6 (typically −40° C.). As a minimum, gasflow estimate may be needed. This can preferably be taken from a flowmeter signal in the transfer circuit for example. But this can be alsocalculated from the signal of other instruments (e.g. a pressure drop orpressure change in the source 2 such as buffer(s)). To improve theaccuracy of cooling power calculation, other measured values may betaken into account such as gas pressure upstream the heat exchanger 7,gas pressure downstream the heat exchanger 7, gas temperature upstreamthe heat exchanger, ambient temperature, temperature of the heatexchanger.

As illustrated in FIG. 7 a cooling power demand signal 24 will causeelectronic controller 21 to acts on compressor 8 and bypass valve 10 tofit with the demand.

The device might also be put in a standby mode (between two fillings).

During this standby mode the heat exchanger 7 might be kept at atemperature that allows a quick start of a refuelling (with a predefinedtime period, for example within 60 s).

This requirement may define the maximum temperature of the heatexchanger 7 during standby mode. For example, if the refrigerationsystem is capable to cool the heat exchanger 7 by 20° K within 60 s,then the active cooling during standby mode shall start when the heatexchanger 7 temperature is above a predefined threshold, for exampleabove −18° C.

If the system is at a low temperature (for example heat exchangertemperature below a first standby temperature threshold, for examplebelow −20° C.) the system is put/kept in standby mode. The compressor isthen preferably switched off.

During standby mode, the liquid refrigerant warms up and the pressure inthe refrigerant cooling loop circuit 20 will increases.

To reduce the pressure in the refrigerant cooling loop circuit 20(pressure increases beyond a preset limit), the cooling source 12 mightbe started to produce or provide cold to the refrigerant circuit.

In case the temperature of the heat exchanger 7 must be lowered (ormaintained cold), the compressor 8 might be started. The start ofcompressor 8 will cause flow in the loop and a reduction of the pressureat its inlet.

If during standby mode the heat exchanger 7 warms up too much, it ispreferably cooled again.

At this operating scenario the time to reach the low temperature is notimportant. Thus the compressor 8 can be operated at the speed with thehighest efficiency (typically its lowest speed).

At minimum speed of the compressor 8, the cooling power is for example10 to 20 kW. This is enough cooling power to cool a typical heatexchanger by 30° K within 120 sec. The minimum operating time of thecompressor 8 might be fixed (for example 120 s). Thus there might be noneed for a higher compressor speed during this standby cooling of theheat exchanger 7.

For example, if the heat exchanger 7 temperature T17 (sensor “19” atFIG. 8) falls below first standby temperature threshold (“TS1” at FIG. 8and for example equal to −37° C.), the refrigeration system (thecooling) or compressor 8 can switched off (on maintained switched off,see ref. 25 at FIG. 8). The heat exchanger 7 temperature can be forexample be measured via temperature sensor 19 or calculated based onother parameter(s).

However, if this temperature T17 is above a second standby temperaturethreshold TS2 (for example above −20° C. or the like) the refrigerationsystem is (or can) be switched on (see “Y” and ref. 26 at FIG. 8).Otherwise the refrigeration system (the cooling) or compressor can beswitched off (on maintained switched off, see ref. 25 at FIG. 8.

The electronic controller 21 may control the refrigeration system sothat the set point of the refrigerant temperature at the heat exchangerinlet is a predefined temperature, for example −40° C.

Thus the electronic controller 21 may regulate the evaporationtemperature, for example measured at the inlet of the heat exchanger 7.If this temperature increases too much a pressure setpoint at compressor8 inlet may be decreased (i.e. the temperature to be achieved at theheat exchanger inlet).

The expected pressure losses via the heat exchanger 7 and the compressorsuction line might be less than 1 bar. Thus, the effect on theevaporation temperature due to pressure losses can be said less than 2°K in case refrigerant is CO2.

If a different refrigerant is used the temperature effect might be muchbigger.

The electronic controller 21 may control the temperature differencebetween inlet 18 and outlet 17 of heat exchanger 7. If the heatexchanger warms up (given by temperature differential ΔT increase) seereference 27 and arrow “Y” at FIG. 6, the controller 21 can open theexpansion valve 10 (see reference 122 at FIG. 6).

As the heat exchanger 7 cools down, the temperature differentialdecreases (see arrow “N” at FIG. 6) and the electronic controller 21will close expansion valve 10 (see reference 23 at FIG. 6).

Thus, the amount of refrigerant flowing in the heat exchanger 7 can becontrolled based on this temperature differential (between inlet andoutlet). If the differential temperature increases the output of thecontroller 21 increases and more refrigerant is sent to the heatexchanger (and vice versa). This can be controlled as feed forwardcontrol signal on the valve 10.

The minimum output might be adjusted in such a way that at zero load thesuperheat temperature at the inlet of the compressor 8 is around apredefined temperature (for example +10° K).

In case of a “standby cooling” the set point can be higher, for example+20° K.

The electronic controller 21 can control the compressor 8 speed and thebypass valve 15 to maintain a constant pressure at the inlet of thecompressor 8.

The superheat control (temperature control) is preferably always inoperation. In case the superheat temperature drops too low the expansionvalve 10 can be closed as required.

Preferably, if the superheat temperature at the inlet of the compressoris too low the expansion valve 10 is closed independent of the actualcooling demand.

In case the superheat temperature increase too much the expansion valve10 can be opened as required.

If the superheat temperature at the inlet of the compressor is too lowthe hot gas bypass valve 15 can be opened.

To avoid complete closing of the expansion valve 10 valve, a minimalopening of the expansion valve 10 can be set. This minimum opening canbe set such that the suction temperature at the compressor 8 inlet isalways sufficiently superheated due to the hot bypassed gas injection.

In addition to the advantages above, the device may allow a very fastchange in cooling power while maintaining a constant evaporationpressure and sufficient superheat at the suction of the compressor 8.

When the device 1 is in the standby mode, the refrigerant (typicallyliquid CO2) downstream of condenser heat exchanger 9 warms up and mayevaporate leading to a pressure increase on the discharge side of thecompressor 8. One solution is to start the cooling source 2 forproviding cold and lowering the refrigerant pressure. To reduce thenumber of starts of the cold source 12, as illustrated at FIG. 9, thedevice may comprise an expansion vessel 29 comprising an inlet connectedto the refrigerant cooling loop circuit 20 at the outlet of thecompressor 8 side. The expansion vessel 29 comprises an outlet connectedto the refrigerant cooling loop circuit 20 at the outlet of thecompressor 8 side. The device comprises set of valves 28, 30 forcontrolling the flow of refrigerant from the circuit 20 (downstream thecompressor outlet) to the expansion vessel 29 and from the expansionvessel 29 to the circuit 20 (upstream the compressor 8 inlet), Theelectronic controller 21 may be configured to open the inlet valve 28 tothe expansion vessel 29 until the pressure downstream the compressor 8is below a certain value (typically open at 35 barg) and dose at presetvalue (for example 33 barg).

When the temperature of heat exchange 7 is too high or when the pressurein the expansion vessel 29 is too high (for example above 15 barg) thecold source 12 might be started and the compressor 8 might be started.Outlet valve 30 of expansion vessel 29 might be opened and the pressurein the expansion vessel 29 is thus reduced to appropriate value again(10 barg for example).

While the invention has been described in conjunction with specificembodiments thereof, it is evident that many alternatives,modifications, and variations will be apparent to those skilled in theart in light of the foregoing description. Accordingly, it is intendedto embrace all such alternatives, modifications, and variations as fallwithin the spirit and broad scope of the appended claims. The presentinvention may suitably comprise, consist or consist essentially of theelements disclosed and may be practiced in the absence of an element notdisclosed. Furthermore, if there is language referring to order, such asfirst and second, it should be understood in an exemplary sense and notin a limiting sense. For example, it can be recognized by those skilledin the art that certain steps can be combined into a single step.

The singular forms “a”, “an” and “the” include plural referents, unlessthe context clearly dictates otherwise.

“Comprising” in a claim is an open transitional term which means thesubsequently identified claim elements are a nonexclusive listing i.e.anything else may be additionally included and remain within the scopeof “comprising.” “Comprising” is defined herein as necessarilyencompassing the more limited transitional terms “consisting essentiallyof” and “consisting of”; “comprising” may therefore be replaced by“consisting essentially of” or “consisting of” and remain within theexpressly defined scope of “comprising”.

“Providing” in a claim is defined to mean furnishing, supplying, makingavailable, or preparing something. The step may be performed by anyactor in the absence of express language in the claim to the contrary.

Optional or optionally means that the subsequently described event orcircumstances may or may not occur. The description includes instanceswhere the event or circumstance occurs and instances where it does notoccur.

Ranges may be expressed herein as from about one particular value,and/or to about another particular value. When such a range isexpressed, it is to be understood that another embodiment is from theone particular value and/or to the other particular value, along withall combinations within said range.

All references identified herein are each hereby incorporated byreference into this application in their entireties, as well as for thespecific information for which each is cited.

What is claimed is:
 1. A device for refuelling containers withpressurized gas, comprising a pressurized gas source, a transfer circuitthat comprises one upstream end connected to the pressurized gas sourceand at least one downstream end intended to be removably connected to acontainer, a refrigeration system for cooling gas flowing from thepressurized gas source prior to entry of the flowing gas into thecontainer, and a bypass regulating valve, the refrigeration systemcomprising a refrigerant cooling loop circuit which comprises, arrangedin series, a compressor, a condenser section, an expansion valve, and anevaporator section, wherein: the refrigeration system further comprisesa cold source, which is in heat exchange with the condenser section, aheat exchanger that is located in the transfer circuit, and a bypassconduit; the heat exchanger comprises a heat exchange section adaptedfor exchanging heat between the evaporator section and gas flowing inthe transfer circuit; the bypass conduit comprises an upstream end whichis connected to an outlet of the compressor and a downstream end whichis connected to the refrigerant cooling loop circuit upstream an inletof the compressor; the bypass conduit bypasses the condenser section andthe expansion valve; and the bypass regulating valve is adapted forcontrolling a flow of refrigerant flowing into the bypass conduit. 2.The device of claim 1, wherein the downstream end of the bypass conduitis connected to an outlet of the heat exchanger of the transfer circuitat a position that is closer to the refrigerant outlet of the heatexchanger than to the compressor inlet.
 3. The device of claim 1,wherein the downstream end of the bypass conduit is connected to theoutlet of the heat exchanger of the transfer circuit at a position thatis between 1-40 cm after the outlet of the evaporator section or 1-40 cmafter the outlet of the heat exchanger.
 4. The device of claim 1,wherein the downstream end of the bypass conduit is connected at anoutlet of the heat exchanger of the transfer circuit.
 5. The device ofclaim 1, wherein the bypass regulating valve is a controlled valve ableto be set in a closed position or a plurality of open positions forvarying the flowrate of refrigerant flowing in the bypass conduit, thedevice further comprising an electronic controller connected to thebypass valve and configured for controlling the opening of the bypassregulating valve.
 6. The device of claim 5, wherein the compressor is avariable speed compressor and the electronic controller is connected tothe compressor and configured for controlling a speed of the compressor.7. The device of claim 5, wherein the electronic controller is connectedto the expansion valve and configured for controlling a cooling powerthat is produced by the refrigeration system via the control of theopening of the expansion valve.
 8. The device of claim 5, furthercomprising a differential temperature sensor system measuring adifference between a temperature of refrigerant in the refrigerantcooling loop circuit at an outlet of the heat exchanger and atemperature of refrigerant in the cooling loop circuit at an inlet ofthe heat exchanger, the electronic controller being configured forcontrolling cooling power produced as a function of the difference intemperature.
 9. The device of claim 5, wherein the electronic controlleris configured to generate or receive a signal indicative of coolingpower needed at the heat exchanger for cooling a flow of gas in thetransfer circuit through the heat exchanger and, in response, forcontrolling the cooling power produced by the refrigeration systemaccordingly.
 10. The device of claim 9, wherein the signal indicative ofthe cooling power needed at the heat exchanger comprises at least oneof: a quantity or flowrate of gas flowing through the transfer circuit,a temperature of gas flowing through the transfer circuit, a pressure ofgas flowing through the transfer circuit, a pressure value or pressurechange in the gas source, and a wireless signal.
 11. A process forrefuelling containers with pressurized gas using a device comprising agas source, a transfer circuit for transferring compressed gas from thegas source to a container, the process comprising the steps of: coolinga heat exchanger located in the transfer circuit, the heat exchangerbeing in heat exchange with the gas flowing from the source to thecontainer(s), the step of cooling comprising the production of a coolingpower in a evaporator section of a refrigerant cooling loop circuit, thecooling loop circuit comprising, arranged in series, a compressor, acondenser section, an expansion valve and the evaporator section, thecondenser section being in heat exchange with a cold source; andcontrolling a quantity of refrigerant compressed by the compressor whichis reinjected via a bypass conduit upstream the compressor, withoutflowing via the condenser section and the expansion valve.
 12. Theprocess of claim 11, wherein the pressurized gas is hydrogen and thecontainer is a gaseous hydrogen tank.
 13. The process of claim 11,wherein a downstream end of the bypass conduit is connected to an outletof the heat exchanger of the transfer circuit at a position closer to anoutlet of the heat exchanger that to an inlet of the compressor.
 14. Theprocess of claim 11, wherein the downstream end of the bypass conduit isconnected to the outlet of the heat exchanger of the transfer circuitbetween 1-40 cm after the outlet of the evaporator section or the outletof the heat exchanger.
 15. The process of claim 11, wherein thecompressed gas reinjected via a bypass conduit upstream the compressoris reinjected at an outlet of the heat exchanger.
 16. The process ofclaim 15, further comprising the step of regulating a suction pressureat an inlet of the compressor to a predetermined pressure level viacontrol of a speed of the compressor and a quantity of refrigerantreinjected via a bypass conduit upstream the compressor.
 17. The processof claim 11, wherein the bypass conduit includes a bypass valve and saidprocess further comprises the step regulating a temperature ofrefrigerant at an inlet of the compressor on a predetermined temperatureset point via control of a speed of the compressor and a degree ofopening of the bypass valve.
 18. The process of claim 11, furthercomprising the step of controlling a cooling power produced in theevaporator section of the refrigerant cooling loop circuit via controlof an opening of the expansion valve.
 19. The process of claim 11,further comprising the step of controlling a cooling power produced inthe evaporator section of the refrigerant cooling loop circuit as afunction of a temperature differential between a temperature ofrefrigerant in the refrigerant cooling loop circuit at an outlet of theheat exchanger and a temperature of refrigerant in the cooling loopcircuit at an inlet of the heat exchanger.
 20. The process of claim 11,further comprising the step of controlling cooling power produced at theevaporator section of the refrigerant cooling loop circuit as a functionof a signal indicative of a cooling power demand at the heat exchanger,said signal including at least one of: a quantity or flowrate of the gasflowing through the transfer circuit, a temperature of the gas flowingthrough the transfer circuit, a pressure of the gas flowing through thetransfer circuit, a pressure or pressure change in the gas source, ademand from a user for refuelling a container, and a wireless signal.21. The process of claim 11, wherein it comprises a step of directingsome refrigerant of the refrigerant cooling loop circuit to an expansionvessel for lowering a pressure in the refrigerant cooling loop circuitbelow a predetermined value.
 22. The process of claim 21, wherein, whena pressure in the expansion vessel is above a predetermined value, andsaid process further comprises a step of providing cold to therefrigerant cooling loop circuit via the cold source and withdrawing gasfrom the expansion vessel to the refrigerant cooling loop circuit.